Modified rubber particles and compositions including the same

ABSTRACT

Modified scrap rubber particles, a method for forming the modified rubber particles and compositions including the modified rubber particles. The rubber particles are impregnated with at least one polymerizable monomer and polymerized to impregnate the rubber particles with a polymer. The impregnated polymer provides the modified rubber particles with improved properties which increase the potential uses for recycled scrap rubber. The modified rubber particles are useful in surface coatings, such as latex paint or powder coatings and can be used as a soil substitute.

This application claims priority to Provisional U.S. Patent Application,Ser. No. 60/615,467, filed on 01 Oct. 2004. The co-pending ProvisionalPatent Application is hereby incorporated by reference herein in itsentirety and is made a part hereof, including but not limited to thoseportions which specifically appear hereinafter.

BACKGROUND OF THE INVENTION

This invention is directed to modifying scrap tire rubber for use in oras other beneficial and desirable products.

Almost 3 million tons of scrap tires are annually generated in NorthAmerica. Among the rubber recycling approaches, size reduction is afeasible approach for the most beneficial reuse of these materials.Currently, there are limited applications for the size reduced rubberparticles, and development of new products is essential to expandinguseful applications. One restricting factor on reusing rubber particlesis the hydrophobic nature that limits the use to only non-aqueous media.

Polymers are generally classified as thermoplastics and thermosets.Thermoplastic polymers can generally be melted and recycled usingheating and remolding processes. Thermoset polymers are crosslinked and,once they are set, the simple approach of melting and reforming into anew shape does not apply to them. Recycling of thermoset polymers isthus a challenging technical problem. Vulcanized rubber materials arethermoset polymers, and scrap tires represent the largest stream ofwaste rubber materials. Over 250 million tires (about one tire perperson) are annually generated in North America and, for the most part,these are inefficiently used or disposed of in landfills.

More attention has been focused on reusing scrap tires in the past fewyears, but the current applications are generally limited to “low value”applications. Understanding the present markets for scrap tires is a keyto continuation and expansion of the recycling efforts toward highervalue added uses of these materials. Currently, there are typicallythree major markets for scrap tires: tire derived fuel (TDF); civilengineering applications; and crumb rubber applications. In addition,small percentages of scrap tires used are often exported or used inagricultural applications.

Incineration of scrap tires to generate energy is a well-knowntechnology and is the largest market for scrap tires in North America.TDF as a source of energy is probably as efficient, and possibly lessexpensive, than fossil fuels. As late as 1990, the only recyclingapproach for scrap tires was the use of TDF. More environmentallyfriendly applications have been developed since then, such that now onlyabout 50 percent of the total recycled scrap tires are in TDFapplications.

TDF is a sufficient way for reducing the number of stockpiled scraptires. However, a valuable source of raw materials is lost using thisapproach. Possible reuse of scrap tires in new products providesconsiderably more energy than simply burning.

Civil engineering is a fast growing and the second largest market forscrap tires. In the typical civil engineering application, shredded tireis used where there is an economic benefit as compared to the price ofsoil or other fill materials. The two major factors contributing to thedynamic growth of this market are the existence of a considerable amountof tire shreds from stockpile abatement projects and availability ofsignificant guidelines and information for shredded tire in civilengineering applications. Civil engineering applications are notconsidered high value added uses of scrap tires, because in mostapplications the rubber particles are used as a replacement forgenerally inexpensive materials like soil.

Size reduction seems to be a promising recycling approach for beneficialuses of scrap tires in high performance products. Size reductiongenerally refers to grinding the vulcanized rubber into shreddedparticles in the typical size range of 25 mm to 150 mm. Further sizereduction of the shredded materials into smaller particles (less than2000 microns) is defined as pulverization. According to ASTM D 5603-96,the recycled rubber particles are classified as coarse and fineparticles. Rubber particles in the size range of 2000 microns to 425microns are coarse particles and the particles smaller than 425 micronsare classified as fine particles.

Today, there are four major applications of crumb rubber usage: rubbermodified asphalt (RMA), molded products, tire/automotive industry andsport surfacing. These applications could be considered as higher valueadded use of recycled rubber materials, compared to the civilengineering and TDF applications discussed above.

The crumb rubber applications have a limited market compared to theother applications. An important factor impacting this market is theimbalance in supply and demand of crumb rubber materials. To increasedemand, there is a need for more focus on developing more products fornew applications.

Direct addition of rubber particles into the matrix of another polymerthat is incompatible with rubber particles generally results in poormechanical properties of the produced materials. Poor interfacialadhesion between surfaces of the rubber particles with matrix istypically the main reason for these failures. Surface modification ofthe rubber particles, or addition of a compatiblizer, may enhance themechanical properties of the resulting composite materials. The moldedproduct of the binder and rubber particles might have limitedapplication due to the particular shape of the mold used. A broaderrange of applications could be obtained without using a mold if thebinder is also in the particulate form. The potential application ofsuch composite materials is in polymeric surface coatings such aswaterborne polymeric coatings or dry powder coatings. Waterbornepolymeric emulsions are the most suitable choice of binders inparticulate form. However, recycled rubber particles have a very poordispersibility in aqueous media due to their hydrophobic nature.Addition of a hydrophilic character to hydrophobic rubber particleswould allow their utilization in such media.

There is a need for a method of modifying reclaimed rubber particlesfrom scrap tires to make them more useable in higher value applicationsand products. There is a need for a modified rubber particle that hashydrophilic properties.

SUMMARY OF THE INVENTION

A general object of the invention is to modify scrap rubber particles toallow for broader and more valuable uses.

A more specific objective of the invention is to overcome one or more ofthe problems described above.

The general object of the invention can be attained, at least in part,through a method of forming a composition including rubber particles.The method includes providing a quantity of the rubber particles, andimpregnating the rubber particles with a first polymerizable monomerthat comprises a hydrophobic monomer. The first polymerizable monomer ispolymerized to form modified rubber particles.

The invention further comprehends a surface coating material comprisinga quantity of rubber particles including an impregnated polymer.

The invention still further comprehends a modified rubber particle, suchas a rubber particle impregnated with a polymer including a hydrophobicmonomer.

This invention provides a novel approach for use of recycled rubberparticles, such as in aqueous media applications. Water dispersiblerubber particles are provided by preparation of amphiphilic particulatephase interpenetrating polymer networks (PPIPNs) on a matrix of recycledrubber particles using, for example, poly(acrylic acid) (PAA).Solid-state shear extrusion (SSSE) pulverization processes can be usedto obtain a fine rubber powder. The particles produced by theseprocesses have a very high surface area compared to those produced byother processes, generally due to the resulting irregular shape. Inaddition, the produced particles are believed to be partiallydevulcanized due to the high shear and compression forces applied duringthe pulverization process. Lower crosslinking densities of the rubberparticles make them more suitable for chemical modification andadditional processing.

One potential application of modified rubber particles provided by thisinvention is as an additive for surface coatings, such as waterbornepolymeric coatings or paints. High solid, but low-volatile organiccompounds (VOC) polymeric coatings can be prepared by addition of themodified rubber particles of this invention into a commerciallyavailable self-curing waterborne emulsion. The impregnated polymers,e.g., the acid groups in PAA, improve the adhesion of the coatings tosteel substrate while the elastic behavior of the rubber particlesprovides higher impact strength.

These and other objects and features of this invention will be betterunderstood from the following detailed description taken in conjunctionwith the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plot summarizing the size distribution of exemplary swollenrubber particles dispersed in toluene (open circles) using laserdiffraction technique and the corrected size distribution for unswollenparticles (solid circles).

FIG. 2 is a plot summarizing the size distribution of Sample 5 dispersedin water.

FIG. 3 is a plot summarizing the swelling degree of rubber particlesbased on the volume fraction of acrylic acid monomer in the initiallyprepared reaction mixtures of Example 1.

FIG. 4 is a plot summarizing the weight fraction of the acrylic acidmonomer absorbed by the swollen rubber particles after reaching theequilibrium swelling state.

FIG. 5 is a plot summarizing the fractional monomer conversion obtainedexperimentally for Samples 3, 5 and 7.

FIG. 6 is a plot summarizing the composition of the poly(acrylic acid)yield in the rubber particles, with the total poly(acrylic acid)including poly(acrylic acid) formed in the rubber particles anddissolved in aqueous phase of the reaction.

FIG. 7 is a plot summarizing the differential scanning calorimetryresults for unmodified rubber particles compared to Samples 3, 5 and 7.The lines show the T_(g) of the poly(acrylic acid) phase in thecomposite particles.

FIG. 8 is a plot summarizing the weight loss change of unmodified rubberparticles compared to Samples 3, 5 and 7 due to thermal degradationunder the purge of nitrogen gas.

FIG. 9 shows the differential thermo-gravimetric analysis of theunmodified rubber particles compared to Samples 3, 5 and 7.

FIG. 10 summarizes the resistance of the prepared example surfacecoatings to the effects of rapid deformation, both intrusion andextrusion.

FIG. 11 summarizes the hardness of the prepared example surfacecoatings.

DESCRIPTION OF PREFERRED EMBODIMENTS

This invention provides a method of modifying the chemical structure ofrubber particles, such as rubber particles obtained from post-consumerrubber items and tire rubber. The modified rubber particles of thisinvention have uses in various applications, some of which are discussedfurther below.

The method according to this invention begins with rubber particles. Therubber particles can include one or more of various types of rubberparticles, but the method of this invention has particular usefulnessusing scrap tire rubber. The tire tread portion of the scrap tiresgenerally provides the most desirable rubber for use in this invention,due to the higher purity of the rubber in the tread portion. The methodof this invention provides a useable product from post-consumer tirerubber waste. The tire rubber is desirably reduced to small particlesusing means available to those skilled in the art. The rubber particlesused in a method according to one embodiment of this invention desirablyhave an average particle diameter of about 75 microns to about 1000microns.

In one embodiment of this invention, the tire rubber is pulverized, suchas according to a solid-state shear extrusion (SSSE) pulverizationprocess, to obtain a fine rubber powder. In an SSSE process according toone embodiment of this invention, rubber granulates are subjected tocompression shear strain in a single screw extruder. The screw designprovides a decreasing channel depth to exert compression, while therelative movement of the screw with respect to the barrel wall ensuresthe shearing of the granulates. Cooling elements remove the heatdissipated during pulverization to reduce or eliminate agglomeration ofthe fine particles and the viscoelastic relaxation of the stresses atelevated temperatures. Suitable SSSE pulverization processes aredisclosed in U.S. Pat. No. 5,904,885, issued on 18 May 1999, toArastoopour et al. The particles produced by SSSE processes generallyhave a very high surface area compared to those produced by otherprocesses, due to their irregular shape. In addition, the producedparticles are partially devulcanized due to high shear and compressionforces applied during the pulverization process. Lower crosslinkingdensities of the rubber particles make them more suitable for chemicalmodification and additional processing.

In the method of one embodiment of this invention, the rubber particlesare impregnated with a reaction mixture including at least one type ofpolymerizable monomer, and desirably a polymerization initiator. In asubsequent step, the impregnated rubber particles are placed in achemical reactor and undergo a polymerization reaction of the absorbedmonomer(s) inside the rubber network. The resulting modified rubberparticles are impregnated with a polymer formed of the polymerizedmonomer(s).

Modification of the rubber particles according to the process of thisinvention provides the rubber particles with particulate phaseinterpenetrating polymer networks (PPIPNs). The resulting polymersextend through the porous matrix of the rubber particles and provide therubber particles with different and useful properties. HydrophobicPPIPNs are produced by the method of this invention when a hydrophobicpolymer is formed by the reaction formulation. Modification of rubberparticles through the formation of hydrophobic PPIPNs desirably enhancesthe internal structure of the rubber particles. One advantage of thisapproach is to add a thermoplastic behavior to the elastic rubberparticles to make them suitable for further processing by melting andmolding. Another benefit is the introduction of reactive functionalgroups to the rubber particles to enable their use as reactive agents inapplications such as powder coatings. Amphiphilic PPIPNs are producedwhen a hydrophilic polymer is formed by the reaction formulation.Modification of rubber particles through the formation of amphiphilicPPIPNs results in addition of a hydrophilic character to the internaland external structure of hydrophobic rubber particles. The resultingmodified rubber particles are water dispersible and suitable for use ina variety of aqueous media applications, such as additives to waterbornepaints.

In one embodiment of this invention, the rubber particles areimpregnated with a polymerizable monomer, a swelling agent and aninitiator. The swelling agent swells the rubber particles, i.e.,increases the size of each rubber particle and its porous matrix, toenhance the permeation of the impregnated polymerizable monomer withinthe rubber particles. The swelling agent can include any of variouschemicals known to swell rubber particles, such as toluene, and can evenbe a polymerizable monomer, such as styrene. In one embodiment therubber particles are impregnated with a monomer mixture where a firstpolymerizable monomer, e.g., a hydrophobic monomer such as styrene, actsas a swelling agent and a second polymerizable monomer, e.g., acrylicacid monomer, is provided for improving the physical and/or chemicalproperties of the rubber particles after a polymerization reaction.

An ionic amphiphilic PPIPN is formed in rubber particles according toone embodiment of this invention using acrylic acid polymerization. Therubber particles are soaked in and impregnated with a de-aerated mixtureof acrylic acid, toluene (as a swelling agent) and an initiator, such as2,2′-azobisisobutyronitrile (AIBN). The toluene promotes swelling of therubber, thereby increasing the interstitial molecular space in therubber matrix and allowing the acrylic acid monomer to impregnate therubber particles. The swollen/impregnated particles are desirablycentrifuged to remove excess monomer solution and placed as an aqueoussuspension in a polymerization reactor to create modified rubberparticles. The ionic strength of the aqueous phase can be manipulated byaddition of an electrolyte, such as sodium chloride electrolyte (0.1M,1M), to prevent monomer desorption from the rubber particles. Adjustingthe pH of the system, e.g., decreasing the pH by addition ofhydrochloric acid or similar acid, is an alternative means for reducingor eliminating monomer desorption from the rubber particles.

A non-ionic amphiphilic PPIPN is formed in rubber particles according toanother embodiment of this invention using vinyl acetate monomer. As thevinyl acetate monomer is only slightly water-soluble, it is generallynot necessary to manipulate the ionic strength of the aqueous phase, asdiscussed above. However, toluene is still useful as a swelling agentdespite the vinyl acetate's closer solubility parameter to the rubber,as the moderate polar nature of the vinyl acetate reduces its ability toswell the rubber. After impregnating the rubber particles with the vinylacetate monomer, the vinyl acetate is polymerized to polyvinyl acetate(PVAc). A hydrolysis step using a methanol/sodium hydroxide solution canbe used to convert the polyvinyl acetate to hydrophilic polyvinylalcohol (PVA).

In another embodiment of this invention, a quantity of rubber particlesis impregnated with a first polymerizable monomer that is a hydrophobicmonomer. The hydrophobic monomer can be polymerized to form ahomopolymer or used in combination with a second polymerizable monomerto form a copolymer, as discussed further below.

In one embodiment of this invention, the rubber particles areimpregnated with a monomer mixture including a first polymerizablemonomer and a second polymerizable monomer that differs from the firstpolymerizable monomer. When polymerized, the first and secondpolymerizable monomers form, and impregnate the modified rubberparticles with, a copolymer.

Various monomers and combinations of monomers are available forimpregnating the rubber particles according to this invention. Theresulting impregnated polymer, either a homopolymer or copolymer, can behydrophilic or hydrophobic, thereby providing the modified rubberparticles with various and different chemical and/or physicalcharacteristics. Examples of monomers suitable for use as the firstand/or second polymerizable monomer include, without limitation,styrene, methyl methacrylate, butyl acrylate, glycidil methacrylate,hydroxy ethyl methacrylate, acrylic acid, methacrylic acid, vinylacetate, and combinations thereof. As will be appreciated, somehydrophobic monomers can be used to form hydrophilic polymers. Forexample, vinyl acetate is hydrophobic, but after preparation ofpoly(vinyl acetate) a hydrolysis step can convert it (fully orpartially) to hydrophilic poly(vinyl alcohol).

Examples of monomers used for forming a hydrophobic PPIPN on and/orwithin the rubber particles include styrene, methyl methacrylate, butylacrylate and similar monomers. These monomers desirably alter themechanical properties of the rubber particles, for example, to allowfurther processing in a thermal press. Some monomers, such as styreneand methyl methacrylate, add strength and toughness, while butylacrylate is generally known as a soft monomer and can be used to impartflexibility, especially as a comonomer with other monomers. Othermonomers desirably provide chemical functionalities on the rubberparticles that are capable of reaction upon further processing,especially for crosslinking reactions during curing or casting of films.Examples of such monomers include glycidil methacrylate (GMA), whichadds epoxide functionality, and hydroxy ethyl methacrylate, which addshydroxy functionality.

A hydrophobic monomer can desirably be used in combination with a secondpolymerizable monomer, such as from the above listing, to impregnaterubber particles with a copolymer. Incorporating a hydrophobic monomerin a monomer mixture including a second monomer, particularly ahydrophilic monomer, has particular benefit in functioning as a swellingagent, thereby reducing or eliminating the need for toluene as aswelling agent. A hydrophobic monomer can be a more desirable swellingagent because it can be polymerized, and there is no need to remove itfrom the modified rubber particles at the end of polymerization process.Hydrophobic monomers, such as styrene, can also facilitate thepolymerization reaction of acrylic acid inside of the rubber particles,and in one embodiment of this invention, the modified rubber particleinclude rubber particles impregnated with a copolymer of acrylic acidand a hydrophobic monomer, such as styrene.

As discussed above, a polymerization initiator is generally includedwith the impregnating monomer solution and used to polymerize theimpregnated monomers. As will be appreciated by those skilled in the artfollowing the teachings herein provided, various and alternativepolymerization initiators are available for use in the method of thisinvention. An example of a suitable polymerization initiator isazobisisobutyronitrile. In one embodiment of this invention, thepolymerization reaction occurs with the polymerizable monomerimpregnated rubber particles disposed within an aqueous suspension.

Optionally, a bifunctional crosslinking monomer, or a crosslinkingagent, is used in the polymerization to induce crosslinking of theimpregnating polymer phase. In such case, the interpenetrating polymernetwork (IPN) is known as a full-IPN, as opposed to the “semi-IPNs”discussed above. Examples of crosslinking monomers are divinyl benzene,ethylene glycol diacrylate (EGDA), and ethylene glycol dimethcrylate(EGDMA).

Modification of rubber particles through the method of this inventionresults in production of advanced rubber materials. The modified rubberparticles of this invention render the rubber particles useful innumerous applications for which the original, unmodified rubberparticles would not be useable. Some exemplary applications arediscussed herein below for illustration, but this list is by no meansexhaustive.

As discussed above, modification of rubber particles with hydrophilicpolymers provides a hydrophilic character to the internal and externalstructure of hydrophobic rubber particles. The resulting amphiphilicPPIPNs are water dispersible and render the modified rubber particlessuitable for use in a variety of aqueous media applications, such as theexemplary embodiments discussed below.

One exemplary application of the modified rubber particles of thisinvention having an interpenetrating hydrophilic polymer is in theproduction of water-borne surface coatings. The water dispersibility ofthe amphiphilic PPIPNs enables the use of the modified rubber particlesas additives to, for example, waterborne paints. The amphiphiliccharacter results in strong adhesion of the waterborne paints to themodified rubber particles. The result is the masking of the black colorof the rubber particles with any of a variety of color polymericcoatings.

The modified rubber particles can be utilized as a texturing additiveand/or an impact modifier in water-borne latex formulations. As theparticles are water dispersible, the latex particles will generallysurround the modified rubber particles. When the coating is subsequentlydried, and as film formation occurs in the latex phase, the continuousfilm will not only form on the surface of the substrate to which thecoating is applied, but also on the surface of each modified rubberparticle. Concurrently, hydrogen bonding between polar groups of theimpregnated polymer and those on the surfactant molecule that isstabilizing the latex, will help stabilize the composite coating andensure that no phase separation occurs. In contrast, if unmodifiedrubber particles (or another hydrophobic compound) are added to a latexpaint or other water-borne coating, the resulting coating will beunstable due to phase separation and an inherent incompatibility of itscomponents. Unlike the coating according to this invention, suchcoatings will generally not withstand mechanical abrasion or chemicalattack. In most instances, the presence of the added unmodified rubberparticulate phase will interfere with the film formation process, andwill result in the formation of cracks and deformities in the coatingduring the drying process.

In addition to waterborne coatings or paints, the amphiphilic modifiedrubber particles of this invention can be used in sport surfacing. A mixof amphiphilic modified rubber particles and a waterborne paint can beused in non-slippery tennis or basketball court surfacing by, forexample, a pour-in-place installation techniques known to those skilledin the art. The elastic behavior of the included rubber particles candesirably provide cushioning safety features to such surfaces.

Modified rubber particles of this invention are also useful in othersurface coatings. As discussed above, modification of rubber particlesthrough the formation of hydrophobic PPIPNs enhances the internalstructure of the rubber particles. One advantage of this approach is toadd a thermoplastic behavior to the elastic rubber particles to renderthem suitable for further processing by melting and/or molding. Anotheradvantage is the introduction of reactive functional groups to therubber particles to enable their use as reactive agents in applicationssuch as powder coatings.

Recently, efforts to lower air emissions in the coating industries haveresulted in the substitution of dry powder coatings for liquid paints.The hydrophobic modified rubber particles of this invention are suitablefor use in powder coating material formulations, such as those known andavailable to those skilled in the art. The hydrophobic modified rubberparticles of this invention provide a cost-effective, environmentallysafe means of protecting, for example, steel structures.

In another embodiment of this invention, modified rubber particlesimpregnated with a hydrophilic polymer are used as a soil substitutecomposition. Amphiphilic modified rubber particles of this invention canretain as much water as three times the dry particle weight. Waterretention properties of the amphiphilic modified rubber particles allowfor use in agricultural applications, particularly in remote locationswith minimal water supplies. The water retention properties allow formore efficient use of available water. In addition, in the UnitedStates, fertilizer runoff significantly contributes to ground waterpollution. Applying and using less water should reduce runoff, and lessrunoff potentially also reduces the amount of fertilizer needed.

The intermolecular water absorbing capability of hydrophilic modifiedrubber particles of this invention retain water and generally release itat a slow rate. A slow release of water can significantly reduce theamount of water needed to grow a plant, as well as reduce the number oftime plants or crops need to be irrigated. In several experiments, seedswere planted in a mixture of soil and the modified rubber particles. Theplants grew in the combination soil at a rate similar to a pure soilcontrol. Also, when watering stopped, the plant in the control soil diedin about 1.5 days while the plant in the combination soil lasted forabout 4 days.

In one embodiment of this invention, in addition to absorbing, retainingand releasing water, the modified rubber particles that are added to ormixed with soil include an absorbed aqueous nutrient solution. Thenutrient solution can be absorbed by the modified rubber particlesbefore applying the modified rubber particles to the soil. In addition,the modified rubber particles, once added to the soil, will generallyabsorb nutrient solution, i.e., liquid fertilizer, added to the mixedsoil. The modified rubber particles of this invention can be used forresidential plants, and can provide a watering solution for plants leftunattended for periods of time.

In one embodiment of this invention, the modified rubber particles areused with or in place of soil to grow natural grass in sport stadiums.In addition to providing an efficiently maintainable lawn, the modifiedrubber particles can desirably provide a softer nature to the sportsurface, which in turns may prevent injuries. Using the modified rubberparticles of this invention is likely more desirable than thealternative of simply spreading fine crumb rubber on an existing lawn,as is currently practiced. Applying crumb rubber may pose healthconcerns as the “free” rubber particles can be inhaled by the players,which may result in respiratory issues. The modified rubber particles ofthis invention are desirably integrally mixed with the soil and thegrass roots, thus reducing or eliminating air-borne particles andreducing or eliminating health risks.

In another embodiment of this invention, the amphiphilic modified rubberparticles are used in wastewater treatment applications, such as forstabilization and flocculation of foreign hydrophobic contaminants. Thehydrophilic polymer phase provides a conduit for water to penetrate intothe rubber particles and achieve contact with the hydrophobic rubbermatrix, which desirably provides a domain for the absorption of thecontaminants.

The present invention is described in further detail in connection withthe following examples which illustrate or simulate various aspectsinvolved in the practice of the invention. It is to be understood thatall changes that come within the spirit of the invention are desired tobe protected and thus the invention is not to be construed as limited bythese examples.

EXAMPLE 1

Materials

Waste rubber slabs with an approximate weight percent composition of53.9% natural rubber (SMR-20), 26.9% carbon black (SRF), 10.8% aromaticoil and 8.4% curatives and additives were shredded using a lab-scaleCUMBERLAND grinder, available from Cumberland Engineering Corporation,South Attleboro, Mass. The shredded rubber granulates of about 2-6 mmwere pulverized into particles of different sizes using an SSSEpulverization process. A narrow size fraction of the pulverized rubberparticles in the size range of 250 to 420 microns were collected usingsieving. The collected particles were repeatedly washed with toluene toremove all dirt and soluble additives. An inhibitor-removing column,available from Sigma-Aldrich Co., was used to eliminate methyl ethylhydroquinone (MEHQ) inhibitor from the acrylic acid monomer (99% AAinhibited with 200 ppm MEHQ). Azobisisobutyronitrile (98%, fromSigma-Aldrich) initiator was used as received without furtherpurification. The water used in all experiments was double distilledusing Barnstead distillation columns.

Preparation of Amphiphilic PPIPNs

Ten swelling mixtures containing 10-100 vol. % acrylic acid monomer intoluene were prepared as indicated in Table 1. All mixtures contained0.3 mol % AIBN initiator on a solvent-free basis. 0.5 g of rubberparticles were soaked in the prepared de-aerated swelling mixtures. Theslurries were allowed to equilibrate over night at room temperature andthen centrifuged at 1000 rpm for 5 minutes to remove excessmonomer/solvent. The centrifuged swollen particles were transferred intotest tubes (10 ml KIMAX glass test tube with screw cap) containing a 1molar sodium chloride (NaCl) solution. The prepared samples weredegassed several times and blanketed with nitrogen gas to insure thecomplete removal of oxygen from the test tubes prior to sealing with acap. The test tube samples were placed in a water bath orbital shaker(Lab-line 3540, available from Barnstead International, Dubuque, Iowa)at an agitation speed of 220 rpm. The samples were kept in the shakerfor 48 hours at 65° C. for micro-domain suspension polymerization of theacrylic acid. The polymerized samples were washed with water to removethe salt and any poly(acrylic acid) dissolved in the aqueous phase. Theresulting particles were dried in a vacuum oven at 60° C. for 12 hoursto ensure the complete removal of the remaining solvent (toluene) andwater. TABLE 1 Volume ratio Sample [AA]:[toluene] (ml) Swellingcoefficient Control  0:10 2.75 1 1:9 2.68 2 2:8 2.54 3 3:7 2.37 4 4:61.96 5 5:5 1.58 6 6:4 1.23 7 7:3 1.04 8 8:2 0.79 9 9:1 0.70 10 10:0 0.54Particle Size Distribution (PSD) Measurements

A laser diffraction technique was used to measure the equivalent volumesize distribution of the particulate materials using a Coulter LS 230device, available from Beckman Coulter, Inc., Fullerton, Calif. In thismethod, the suspended particles in a circulating fluid pass through alaser beam cell for size detection. Because the rubber particles arepartially cross-linked, they do not dissolve in any solvent, but theyswell and disperse well in a good solvent like toluene. However, iftoluene is used as the dispersing medium, the PSD measurement has to becorrected to obtain the size of unswollen particles. Assuming aspherical shape for the particles, this correction could be expressedby:r₁=r₂φ₂ ^(1/3)where φ₂ is the volume fraction of the rubber; and r₂ and r₁ are theradii of the swollen and unswollen particles, respectively.

The PSD of the sieve-collected rubber particles in the range of 250-420microns was measured in toluene using a laser diffraction particle sizeanalyzer. As indicated in FIG. 1 and Table 2, the particle sizemeasurement shows both smaller and larger particles than the onesmeasured using the sieves (250-420 microns). Smaller sizes were due todeagglomeration of the particles in toluene, which resulted frompenetration of toluene in the voids between the primary particles.Larger sizes were due to the swelling of the individual particles. Thevolume fraction of rubber in the swollen particles was estimated as 0.29using Equation 1. Each size fraction of the swollen particles wascorrected by this factor to obtain the size distribution of unswollenparticles. As indicated in Table 2, more than 50% of the unswollenparticles were smaller than the lower size limit (250 microns) ofparticle size measured using sieves. This seems to indicate that theparticles produced using the SSSE pulverization process contained alarge amount of agglomerates. TABLE 2 Mode Median Size range Sample(microns) (microns) (microns) Swollen particles 356 349 2-994 Unswollenparticles 231 226 1-708 Sample IP 245 250 1-993

To determine the water dispersibility of the prepared PPIPNs and compareit with the unmodified rubber particles, the PSD of the samples wasmeasured using water as the dispersing medium. The unmodified rubberparticles formed agglomerates larger than the maximum size range of theinstrument (2000 microns) confirming their poor dispersibility in water.However, the produced PPIPNs were water dispersible and their PSD couldbe analyzed in this medium. The PSD of the Sample 5 in water is shown inFIG. 2, and appears to be similar to the distribution of unmodifiedrubber particles in toluene. This could because the produced PPIPNsdisperse better in water due to the formation of hydrophilicpoly(acrylic acid) on the surface of the hydrophobic rubber particles.However, a small amount of agglomerated PPIPNs is observed on the rightshoulder of the PSD, between 700-1000 microns. These could be anindication that a small portion of the very fine particles in theinitial sample does not end-up as PPIPNs. These particles wouldnaturally agglomerate in water and show up as the large size peak inFIG. 2.

Swelling Coefficient Measurement

Approximately 0.5 g of the rubber particles were immersed in separatetest tubes containing each of the swelling mixtures shown in Table 1.The samples were allowed to equilibrate at room temperature for a periodof 24 hours. The swollen particles were centrifuged at a speed of 1000rpm for 5 minutes to remove the excess solvent and then immediatelyweighed. The equilibrium-swelling coefficient was calculated as:${{Swelling}\quad{coefficient}} = \left\lbrack \frac{W_{2} - W_{1}}{W_{1}} \right\rbrack$where W₁ and W₂ are the weights of dry and swollen rubber particles,respectively.

The swelling coefficient of each sample was calculated using the aboveequation and is reported in Table 1. The use of toluene in the reactionmixture was necessary despite the closeness of the solubility parameterof rubber, 19.8 MPa^(1/2), and acrylic acid monomer, 24.6 MPa^(1/2). Asshown in FIG. 3, the swelling degree of the rubber particles decreasesby increasing the volume fraction of acrylic acid in the reactionmixture. Addition of toluene resulted in swelling of the rubber networksand enhancement in absorption of acrylic acid.

The concentration of monomer absorbed by the rubber particles wasinferred from gas chromatography (GC) measurements on the remainingswelling mixtures using a 6890 Spectrometer, available fromHewlett-Packard, Palo-Alto, Calif. The concentration of acrylic acid inthe swelling medium was measured after swelling equilibrium state wasreached and then subtracted from the concentration of acrylic acid inthe initially prepared swelling mixture to calculate the amount ofmonomer absorbed by the rubber particles.

The kinetics of the polymerization reaction was estimated by taking outa sample in intervals of two hours and transferring it to an aluminumpan containing methanol and hydroquinone to stop the reaction. Thefractional monomer conversion “X_(m)” was calculated using gravimetricanalysis: $X_{m} = \frac{p \times W_{IPN}}{M_{0}}$where M₀ is the weight of monomer absorbed by the rubber particles;W_(IPN) is the weight of dried PPIPN samples; and p is the weightfraction of poly(acrylic acid) in the composite particles.

The maximum monomer absorption was achieved in the case of reactionmixture initially containing 50 vol. % monomer, as indicated in FIG. 4.The likely reason is that the reaction mixture was concentrated enoughand the rubber particles were sufficiently swollen with toluene.Addition of monomer in the reaction mixtures containing less than 50vol. % acrylic acid resulted in more absorption of the acrylic acid dueto extended swelling of the rubber particles in these samples. Furtheraddition of acrylic acid to more than 50 vol. % resulted in lessabsorption of monomer by the rubber particles. This is because of thelimited amount of toluene in these reaction mixtures and consequently,low swelling degree of the rubber particles.

Desorption of Monomer into the Aqueous Phase

The polymerization reaction of acrylic was intended to take place withinthe hydrophobic phase (rubber particles) using an oil-soluble initiator(AIBN) and assuming that the acrylic acid monomer remains in theparticles. However, the ionization of acrylic acid at the interface withwater results in desorption of acrylic acid into the aqueous phase ofthe system. By increasing the ionic strength of the aqueous phase andlowering the solubility of acrylic acid in the aqueous phase, desorptionof monomer was controlled during the polymerization reaction. However,the polymerization reaction most likely occurred in the shell region ofthe particles and some desorbed in to the aqueous phase. At low ionicstrength (e.g., 0.1 M NaCl), the poly(acrylic acid) yield in theresulting particles was almost negligible in all samples, indicatingexcessive monomer desorption. This was also confirmed by pH measurementof the aqueous phase. The ionic strength was increased to 1 M NaClelectrolyte and subsequently desorption of the acrylic acid was loweredsubstantially.

Kinetics of Polymerization and Composition of the Prepared PPIPNs

The overall conversion of monomer was calculated and found to exceed 80%in all samples. FIG. 5 illustrates the kinetics of polymerization ofacrylic acid in the selected Samples 3, 5 and 7. The rate ofpolymerization reaction obtained experimentally was much lower thantheoretically expected. Most likely, this resulted from a non-uniformdistribution of acrylic acid in the particles, as the hydrophilicmonomer tends to migrate toward the aqueous interface. Thus, most of thepolymerization reaction occurs in the shell region of the particles,where the available concentration of oil soluble initiator, AIBN, waslower than the total absorbed by the particles. In particular, due to alow concentration of the initiator in Sample 3, the rate ofpolymerization was lower than for Samples 5 and 7 (see FIG. 5). As aresult, the viscosity of the polymerization loci within the swollenparticles increased faster in the case of Samples 5 and 7. It isexpected that the poly(acrylic acid) chains interpenetrated theirmolecular interstices within the rubber network in Samples 5 and 7 morethan Sample 3. The study on the morphology of the produced particles wasfollowed by the thermal degradation analysis of the samples.

FIG. 6 indicates the composition of prepared PPIPN as a function ofmonomer volume fraction in the initially prepared swelling reactionmixture. The maximum poly(acrylic acid) yield was achieved in the caseof Sample 5 that also absorbed the highest amount of monomer in theswelling step (see FIG. 4). FIG. 6 shows that there was a considerabledifference between the total amount of poly(acrylic acid) obtained inthe test tube samples and the interpenetrated poly(acrylic acid) in therubber particles. During the polymerization of acrylic acid, phasesegregation occurs due to difference in hydrophilicity of poly(acrylicacid) and rubber. Thus a large portion of poly(acrylic acid) wasdesorbed into the aqueous phase.

Thermal Characterization

The thermal degradation behavior of the prepared samples was studiedusing a thermal analyzer, Model STA 625, available form PolymerLaboratories, Amherst, Mass. Experiments were conducted in thetemperature range of 35-550° C. under a nitrogen gas purge at scanningrate of 10° C./min. Samples were prepared in open pans containing about10 mg of the composite particles.

FIG. 7 illustrates the thermal behavior of prepared PPIPN samples asmeasured by differential scanning calorimetry (DSC). The DSC tracesshowed two endothermic peaks; one peak in the range of 150-280° C., dueto thermal degradation of poly(acrylic acid), and the second peak in therange of 340-450° C., which reflects the thermal degradation of rubber.The glass transition (T_(g)) temperature of both rubber and poly(acrylicacid) were individually measured as −60° C. and 110° C., respectively.In a multi-phase component polymeric system, the T_(g) value ofcomposite materials indicates the degree of miscibility. Partialmiscibility of the components results in a shift in T_(g) of eachcomponent toward the other and a single T_(g) value could be obtainedwhen the components are completely miscible. The T_(g) value ofpoly(acrylic acid) in the prepared PPIPNs was measured from DSC resultssummarized in Table 3. The T_(g) values of poly(acrylic acid) in thecase of Samples 5 and 7 slightly shifted toward the T_(g) value ofrubber (−60° C.), which indicates a partial interpenetration ofpoly(acrylic acid) chains in the rubber network. To ensure thereproducibility of the results, these measurements were repeated severaltimes and followed by thermo-gravimetric analysis (TGA) of the samples.TABLE 3 T_(g1) DTG_(p1) DTG_(p2) Sample (° C.) (wt. %/° C.) (wt. %/° C.)3 110 −0.06 −0.8 5 105 −0.24 −0.64 7 105 −0.16 −0.68(1 corresponds to PAA phase and 2 relates to rubber phase)

The weight loss of samples due to thermal degradation was obtained fromthe TGA results shown in FIG. 8. These results provide helpfulinformation regarding the composition and phase structure of thesamples. The TGA traces of samples in FIG. 8 show that two major weightloss events are observed in two distinct regions. The first weight losswas due to degradation of poly(acrylic acid) (at about 200-340° C.) andthe second weight loss was due to degradation of rubber (at about340-460° C.). Carbon black and some other additives remain in the formof residues at the temperatures above 500° C. Due to differences betweenthe poly(acrylic acid) content of the samples, the amount of residues atthe end of experiments also differs. Therefore, the residual content canbe used to indicate the composition of prepared PPIPNs, knowing theamount of residues in the unmodified rubber particles is approximately35 wt. % (see FIG. 8).

As indicated in FIG. 8, the amount of residues was the same in the caseof Samples 3 and 7, which means they contain the same amount ofpoly(acrylic acid), as was also confirmed by the weight changemeasurement results shown in FIG. 6. However, different weight lossbehavior due to degradation of poly(acrylic acid) was observed in thetemperature range of 200-340° C. This could be because in Sample 7, someparts of the poly(acrylic acid) chains were deeply interpenetrated andtrapped in the rubber network. Thus, the weight loss of this portion ofpoly(acrylic acid) chains was observed during the degradation of rubbernetwork in the temperature range of 340-460° C.

Table 3 indicates the extent of degradation of sample componentsextracted from FIG. 9. The extent of degradation of unmodified rubberparticles was measured as −0.8 wt. %/° C. In the case of Sample 3, theextent of degradation of rubber chains (DTG_(p2)) was similar tounmodified rubber sample. However, the DTG_(p2) value in the case ofSamples 5 and 7 was smaller than the unmodified rubber sample. Theseresults indicated that more penetration of poly(acrylic acid) within therubber networks occurred in Samples 5 and 7, thus improving the thermaldegradation behavior of the rubber phase in these samples, as shown inFIG. 9. As indicated in FIG. 9, the degradation peak of the rubber phasein Samples 5 and 7 shifted toward higher temperatures compared tothermal degradation behavior of Samples 3 and unmodified rubber.

Thus, amphiphilic composite particles were successfully prepared on amatrix of recycled rubber material. Polymerization of monomer absorbedby the rubber particles resulted in partial interpenetration ofpoly(acrylic acid) in the intermolecular structure of rubber networks.To increase the hydrophilicity of the rubber particles, the absorptionof acrylic acid by the particles was enhanced by addition of toluene asa swelling agent. However, addition of toluene could result in lessinterpenetration of poly(acrylic acid) in the rubber network. Therefore,by adjusting the amount of the solvent in the reaction mixture, thecomposition of the PPIPNs was better controlled. The resulting compositeparticles were water dispersible and suitable for use in aqueous mediaapplications.

EXAMPLE 2

Materials

An inhibitor-removing column (available from Sigma-Aldrich) was used toeliminate methyl ethyl hydroquinone (MEHQ) inhibitor from an acrylicacid (AA) monomer (99% AA inhibited with 200 ppm MEHQ).Azobisisobutyronitrile (98%, from Aldrich) initiator was used asreceived without further purification. A commercially availablewaterborne air curing styrene-acrylic emulsion was obtained from JohnsonPolymer, Racine, Wis. The emulsion's formula was modified by addition oforganic solvents in order to form a film at room temperature. Theorganic solvents included 1-phenoxy-2-propanol (DOWANOL-PPh,Sigma-Aldrich), di(propylene glycol)methyl ether (DPM, Sigma-Aldrich)and di(propylene glycol)butyl ether (DOWANOL-DPnB, Sigma-Aldrich).Unpolished steel panels (10 mm; 20 mm; 0.63 mm) were surface modifiedaccording to the procedure explained in ASTM D 609-95.

Waste rubber slabs with approximate weight percent composition of 53.9%SMR-20 (natural rubber), 26.9% SRF (carbon black), 10.8% aromatic oiland 8.4% curatives and additives were granulated using a lab-scalegrinder. These rubber granulates were pulverized into particles ofdifferent sizes using two similar SSSE pulverization processes. Particlesize measurements were conducted according to ASTM D 5644 and ASTM D5603.

Preparation of Amphiphilic PPIPNs

Swelling mixtures containing 30, 50 and 70 volume percent acrylic acidin toluene were prepared. Toluene was added to the reaction mixtures tomake the rubber particles more receptive to the acrylic acid. Allmixtures contained 0.3 mol % AIBN initiator on a solvent-free basis.About 150 g of the rubber particles having a size range of 250 micronsto 425 microns were sieve collected and soaked in the preparedde-aerated swelling mixtures. The slurries were allowed to equilibrateover night at room temperature and then centrifuged to remove excessmonomer/solvent. The swollen particles were centrifuged and transferredinto a 1000 ml CSTR reactor containing an electrolyte solution andhaving a 200 rpm stirring speed. The electrolyte solution was used tomake the acrylic acid exclusive of the aqueous phase. The reactants werekept in the reactor for 24 hours at 75° C. for micro-domain suspensionpolymerization of the acrylic acid under the purge of nitrogen gas. Thepolymerized samples were washed with water to remove the salt and anypoly(acrylic acid) (PAA) dissolved in the aqueous phase. Then theresulting powder samples were dried in a vacuum oven at 60° C. for 12hours to ensure the complete removal of the remaining solvent and water.Table 4 summarizes the samples made from the three swelling mixtures.TABLE 4 Sample Rubber content (wt. %) PAA content (wt. %) 11 70 30 12 5050 13 70 30Low-VOC Coatings Preparation

The poly(acrylic acid) in the prepared modified rubber particles absorbsa considerable amount of water. Addition of these particles into anemulsion results in absorbing the water in the emulsion and forming athick paste. Therefore, the prepared modified rubber particles were keptin water long enough to reach the equilibrium state before adding themto the emulsion. For room temperature film formation of the preparedsuspensions of particles/emulsion, addition of some organic solvent wasnecessary. However, in all prepared mixtures, the amount of solventadded to the emulsion was kept below the maximum limit of 240 g/l VOC. Aflash rust inhibitor was sufficiently added to the waterborne emulsionto lower the degree of rusting to less than 0.01% of the surface (rustgrade 10) according to ASTM D 610-95. Based on the dry weight of thecoating prepared, modified rubber particles in different amounts wereadded to the emulsion to obtain 30 wt. %, 40 wt. % and 50 wt. % ofmodified rubber particles in the dried coating samples. Uniformthickness coatings were prepared according to ASTM D 823-95 practice E(hand-held blade film application). Addition of Sample 11 particles tothe emulsion to form a film required additional organic solvent, whichexceeds the maximum VOC limit content. This was due to the highconcentration of PAA on the surface of modified rubber particles.Therefore, Sample 11 was not used in the experimental set up. In thecase of Sample 12 and 13, the maximum amount of modified rubberparticles to form a uniform film without exceeding the maximum limit ofVOC content was about 50 wt. % and 40 wt. %, respectively. Table 5summarizes the specifications of the prepared coating samples. TABLE 5Particle wt. % in the dry Thickness^(a) Gloss Sample coating (mils) 20°C. 85° C. 60° C. Control 0 5.1 74.5 87.6 86.2 Sample 12-30 30 22 7.241.4 46.7 Sample 12-40 40 19.8 1.7 14.9 16.7 Sample 12-50 50 20.2 0.55.3 3.8 Sample 13-30 30 19.9 1.8 16 20.8 Sample 13-40 40 24.4 0.2 3.41.9aAccording to ASTM D 1005-95Impact Strength

The coatings on the steel panels were subjected to rapid deformation bya falling weight to determine their damping impact, according to ASTM D2794-93. Two methods for measuring the impact strength were used:intrusion and extrusion. In the intrusion test, the falling weight hitsthe sample on the coating surface and, the in the extrusion test, thefalling weight hits the sample from the backside of the coating samples.FIG. 10 summarizes the resistance of the prepared coatings to theeffects of rapid deformation, intrusion and extrusion.

As shown in FIG. 10, the emulsion prepared control coating had weakintrusion and extrusion impact strength. Addition of the modified rubberparticles to the emulsion significantly improved the intrusion impactstrength of the prepared coatings. The impact strength was improved moreby addition of Sample 13 compared to Sample 12 with the same weight % ofmodified rubber particles (Sample 12-40 vs. Sample 13-40). The reason islikely that the rubber content of Sample 13 was higher than Sample 12,as shown in Table 4. No significant change was observed in the extrusionimpact strength of the samples by addition of modified rubber particles.This might be due to the low adhesion strength of the emulsion itself tothe substrate surface, as will be explained below.

Adhesion Rate

If a coating is to fulfill its function of protecting the substrate, itmust adhere to the surface of the substrate. Tape test methods A and B(ASTM D 3359-97) were conducted on the samples. The tape used in thismeasurement was manufactured by 3M (core series 2-3610). In this testmethod, the adhesion of the coatings to the substrate could be rated bythe adhesion strength of the tape to the coatings. If the tape adheresto the coating surface stronger than the coating to the substrate, itcan peel off the coating from the substrate. This test method measuresthe adhering rate of the coating ranging from 0 (indicating minimumadhesion) to 5 (indicating maximum adhesion). Test method A is for thickcoatings and method B is for thin coatings. The results are summarizedin Table 6. TABLE 6 Adhesion Sample classification Control 0B Sample12-30 5A Sample 12-40 5A Sample 12-50 5A Sample 13-30 5A Sample 13-40 5A

The results indicate that the control emulsion had poor adhesion to thesteel panels. The adhesion of the surface coatings increased upon theaddition of the modified rubber particles to the emulsion. Withoutwishing to be limited by theory, this could be due to the acid groups ofpoly(acrylic acid) on the surface of the modified rubber particles,which create strong adhering bonds with the steel surface, resulting ina better adhesion of the coatings to the substrate.

Abrasion Resistance

Coatings on substrates can be damaged by abrasion. The Taber abrasiontest is a useful method in evaluating the abrasion resistance of thecoatings (ASTM D 4060). In this test, the coated rotating panel underweighted abrasive wheels abrades the coating. The calibrase abrasivewheel type CS-10, available from Taber Industries, was used under a 1 kgload. The weight loss of the coating due to abrasion was recorded foreach sample during 1000 wear cycles. Table 7 summarizes the results.TABLE 7 Weight Weight Weight Weight loss after loss after loss afterloss after 250 cycles 500 cycles 750 cycles 1000 cycles Wear Sample (mg)(mg) (mg) (mg) index Control 37.7 77.6 114.9 149.6 149 Sample 12-30 45.787.5 131.2 171.3 165 Sample 12-40 44.2 90.7 132.8 181.1 183 Sample 12-5058.6 121.9 191.6 271.3 284 Sample 13-30 44.3 86.5 126.8 169.6 167 Sample13-40 66.7 147.8 228.2 319.1 336

The weight loss measurement of the samples in the first 250 cycles isoften less accurate compared to the other cycle measurements because theresults might have been affected by the uneven surface. The wear indexof the coatings was measured using the following equation and theresults obtained from 250 to 1000 wearing cycles:${WearIndex} = \frac{\left( {A - B} \right) \times 1000}{C}$where A is the weight of test specimen before abrasion (mg); B is theweight of test specimen after abrasion (mg); and C is the number ofcycles of abrasion recorded.

The Wear index indicates the abrasion resistance of the coatings. Asshown in Table 7, the control sample had the highest abrasion resistancecompared to the other samples. The likely reason is that the modifiedrubber particles are generally much softer than the emulsion used, andthey abrade faster. However, Samples 12-30 and 13-30 had almost the sameresistance as the control. Thus, controlling the amount of modifiedrubber particles added to the coatings can provide a suitable abrasionresistance.

Hardness

Depending on the elastic behavior of the coatings, different resistanceto deformation can be obtained. The Konig pendulum hardness test wasconducted on the prepared coatings based upon ASTM D 4366-95. This testmethod embodies the principle that the amplitude of oscillation of apendulum touching the surface of a coating decreases more rapidly if thesurface is softer. FIG. 11 summarizes the hardness of the preparedsurface coatings by this test method. As shown in FIG. 11, the hardnessof the prepared surface coatings decreases by addition of more than 40wt. % modified rubber particles.

The results demonstrate the advantages of adding the modified rubberparticles of this invention to waterborne surface coatings. Mechanicalproperties such as impact strength were improved by addition of thesecomposite particles. The hardness of the prepared coatings reducedsignificantly in the prepared coatings, which makes them suitable forsport surface applications. The hydrophilic character of the modifiedrubber particles enables preparing coatings with any color.

Thus, the invention provides a method for modifying rubber particles,particularly recycled rubber, such as from used tires. The improvedproperties of the modified rubber particles of this invention allow forthe used of the recycled rubber in numerous new ways, such as in surfacecoatings or as a soil substitute. It will be appreciated that details ofthe foregoing embodiments, given for purposes of illustration, are notto be construed as limiting the scope of this invention.

Although only a few exemplary embodiments of this invention have beendescribed in detail above, those skilled in the art will readilyappreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention, which isdefined in the following claims and all equivalents thereto. Further, itis recognized that many embodiments may be conceived that do not achieveall of the advantages of some embodiments, particularly of the preferredembodiments, yet the absence of a particular advantage shall not beconstrued to necessarily mean that such an embodiment is outside thescope of the present invention.

1. A method of forming a composition including rubber particles, themethod comprising: providing a quantity of the rubber particles;impregnating the rubber particles with a first polymerizable monomercomprising a hydrophobic monomer; and polymerizing the firstpolymerizable monomer to form modified rubber particles.
 2. The methodaccording to claim 1, wherein the rubber particles comprise pulverizedtire rubber.
 3. The method according to claim 1, wherein the hydrophobicmonomer comprises styrene.
 4. The method according to claim 1, whereinthe rubber particles comprise an average particle diameter of about 75microns to about 1000 microns.
 5. The method according to claim 1,wherein polymerizing the first polymerizable monomer occurs in anaqueous suspension.
 6. The method according to claim 5, additionallycomprising adjusting the pH of the aqueous suspension.
 7. The methodaccording to claim 1, wherein polymerizing the first polymerizablemonomer comprises introducing a polymerization initiator to the rubberparticles.
 8. The method according to claim 7, wherein the initiatorcomprises azobisisobutyronitrile.
 9. The method according to claim 1,additionally comprising impregnating the rubber particles with aswelling agent.
 10. The method according to claim 9, wherein theswelling agent comprises toluene.
 11. The method according to claim 1additionally comprising introducing a crosslinking monomer to the rubberparticles.
 12. The method according to claim 1, additionally comprisingimpregnating the rubber particles with a second polymerizable monomerand polymerizing the first and second polymerizable monomers toimpregnate the rubber particles with a copolymer.
 13. The methodaccording to claim 12, wherein the second polymerizable monomer isselected from a group consisting of methyl methacrylate, butyl acrylate,glycidil methacrylate, hydroxy ethyl methacrylate, acrylic acid,methacrylic acid, vinyl acetate, and combinations thereof.
 14. Themethod according to claim 12, wherein the copolymer comprises ahydrophobic copolymer.
 15. The method according to claim 14, wherein thecomposition comprises a powder coating material, and the methodadditionally comprises adding the modified rubber particles to a powdercoating material formulation.
 16. The method according to claim 12,wherein the copolymer comprises a hydrophilic copolymer.
 17. The methodaccording to claim 16, wherein the composition comprises a waterbornepaint, and the method additionally comprises adding the modified rubberparticles to a waterborne paint formulation.
 18. The method according toclaim 16, wherein the composition comprises a soil substitute, and themethod additionally comprising adding the modified rubber particles tosoil.
 19. The method according to claim 16, additionally comprisingabsorbing an aqueous nutrient solution before adding the modified rubberparticles to the soil.
 20. A surface coating material comprising aquantity of rubber particles including an impregnated polymer.
 21. Thesurface coating material according to claim 20, wherein the polymercomprises a hydrophobic polymer.
 22. The surface coating materialaccording to claim 21, wherein the polymer is selected from a groupconsisting of polystyrene, poly(methyl methacrylate), poly(butylacrylate), poly(glycidil methacrylate), poly(hydroxy ethylmethacrylate), and combinations thereof.
 23. The surface coatingmaterial according to claim 20, wherein the polymer comprises ahydrophilic polymer.
 24. The surface coating material according to claim23, wherein the polymer is selected from the group consisting ofpoly(acrylic acid), poly(methacrylic acid), poly(vinyl alcohol),partially hydrolized poly(vinyl acetate) and combinations thereof. 25.The surface coating material according to claim 20, wherein the surfacecoating is selected from a group consisting of a waterborne paint, apowder coating material, and a sport surface.
 26. A modified rubberparticle comprising a rubber particle impregnated with a polymerincluding a hydrophobic monomer.